Concrete Form Assembly for Square Columns, and Locating Template for Use Therewith

ABSTRACT

A locating template for a non-round concrete form of the type having a round outer tube and an insert assembly installed in the outer tube for defining the desired non-round shape. The locating template can be fit into the end of the channel defined by the insert assembly. The locating template has a crosshair or series of marks indicating the center of the locating template, which corresponds to the center of the channel defined by the insert assembly. The contractor simply marks the outer surface of the outer tube at two or more locations aligned with the crosshair or marks on the locating template. The locating template is removed, and the form is set up on the ground with the marks on the outer tube aligned with the crosshair on the ground. The column can then be poured in the usual manner.

BACKGROUND OF THE INVENTION

The present disclosure relates to non-round (e.g., square/rectangular)concrete forms of the type having a round outer tube and an insertassembly that fits into the outer tube to define the desired non-roundcross-section for the concrete column.

On the jobsite, it is difficult for the contractor to precisely centerthe form at the desired location for the column. Typically thecontractor marks a pair of perpendicular lines forming a “crosshair” onthe floor or ground, which identifies where the non-round column shouldbe centered as well as how the non-round column should be oriented.Since the contractor cannot see the insert assembly in the outer tube,but can only see the outer tube, it is difficult to know when the centerof the insert assembly is properly aligned with the crosshair.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure is directed to a device to address this problemin an inexpensive yet effective way. The device comprises a locatingtemplate that fits into the end of the non-round channel defined by theinsert assembly in the outer tube. The locating template has a crosshairor series of marks indicating the center of the locating template, whichcorresponds to the center of the channel defined by the insert assembly.The contractor simply marks the outer surface of the outer tube at twoor more locations aligned with the crosshair or marks on the locatingtemplate. The locating template is then removed, and the form is set upon the floor or ground with the marks on the outer tube aligned with thecrosshair on the floor or ground. The column can then be poured in theusual manner.

The locating template advantageously can be made of a polymer foammaterial such as expanded polystyrene (EPS). However, there is noparticular limitation on the material of which the locating template canbe made.

The present disclosure also relates to a combination of a concrete formand a locating template as described above. Apart from the locatingtemplate's utility for centering the form on a crosshair, the locatingtemplate also helps support the end of the concrete form to resistcollapsing of the form under pressure, such as when multiple forms arestacked atop one another for shipment. With conventional forms, suchstacking can result in the forms becoming out of round (oval oregg-shaped) because of the significant pressure exerted by a pile offorms.

Additionally, the locating template prevents a fork of a forklift frombeing inserted into the end of the concrete form for lifting the form,which is a common practice employed for loading forms into and unloadingthem from a trailer, but which can cause gouges and/or protrusions onthe inner surface of the form. This is highly undesirable because itresults in unsightly recesses and/or protrusions on the concrete column,which must be patched and/or machined off after the column sets.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the disclosure in general terms, reference willnow be made to the accompanying drawings, which are not necessarilydrawn to scale, and wherein:

FIG. 1 is a perspective view showing a concrete form in accordance withone embodiment of the invention erected on a surface upon which acrosshair has been marked for indicating the desired location of thegeometric center and the desired orientation of the non-round column tobe formed by the concrete form;

FIG. 2 is an end view of the concrete form without any locating templateinstalled;

FIG. 3 is a perspective view of a locating template for the concreteform in accordance with one embodiment of the invention;

FIG. 4 is a perspective view of a locating template in accordance withanother embodiment;

FIG. 5 is a perspective view of a locating template in accordance withanother embodiment;

FIG. 6 is a perspective view of a locating template in accordance withstill another embodiment;

FIG. 7 is a top or plan view of a locating template in accordance with afurther embodiment; and

FIG. 8 is an end view of the concrete form with a locating templateinstalled therein in accordance with one embodiment.

DETAILED DESCRIPTION OF THE DRAWINGS

The present inventions now will be described more fully hereinafter withreference to the accompanying drawings in which some but not allembodiments of the inventions are shown. Indeed, these inventions may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout.

A concrete form 100 in accordance with one embodiment of the inventionis illustrated in FIGS. 1 and 2. The form 100 includes an outer tube 110of circular cross-section, and an insert assembly 120 installed withinthe outer tube. The outer tube can comprise a spirally wound paperboardtube generally as shown, although the invention is not limited to anyparticular type or construction of outer tube. The outer tube can havean inside diameter ranging from about 12 inches to about 48 inchesdepending on the desired size of the concrete column to be produced,although the invention is not limited to any particular diameter. Theinsert assembly 120 defines a central channel C of non-round (square orrectangular being illustrated) cross-section for defining the desiredcross-section for a concrete column.

The insert assembly 120 can be of any suitable construction providingthe desired channel C. In one embodiment for forming a substantiallysquare column as illustrated, the insert assembly is formed by foursegments 122 each forming one respective side of the substantiallysquare channel. Each segment has a length substantially the same as thatof the outer tube and has a substantially constant cross-section overthat length (although a constant cross-section is not a necessity). Eachsegment has an inner surface (i.e., the surface that imparts a desiredshape to the concrete) that is substantially planar and an oppositeouter surface (i.e., the surface that confronts the inner surface of theouter tube 110) that is formed as an angular segment of a cylinder ofsubstantially the same diameter as the inside diameter of the outer tube110. The segments can be formed of any suitable material, including butnot limited to polymer foam material. In the case of polymer foamsegments, each of the segments can be formed as a continuous extrusionof polymer foam material. A suitable non-limiting example of a polymerfoam material that can make up the segments is expanded polystyrene(EPS). The inner surfaces of the segments 122 can be affixed to a linersheet (not shown) that forms the innermost surface of the insertassembly 120 that contacts the concrete.

The axial length of the insert assembly 120 is substantially the same asthat of the outer tube 110 and the insert assembly's opposite ends aresubstantially coincident with the opposite ends of the outer tube. Thus,the channel C has a first opening of non-round (square in theillustrated embodiment) shape at one end of the outer tube and anopposite second opening of non-round shape at an opposite end of theouter tube. Once the form 100 has been vertically erected and braced inposition by suitable bracing (not shown), wet concrete is poured intothe top opening of the channel C until the form is substantially filledwith the concrete. After drying and hardening of the concrete, the formis stripped off the column.

As noted, a difficulty encountered with such non-round concrete forms isthat unlike a round form where the rotational orientation of the roundcolumn is irrelevant and the form can be oriented in any arbitraryrotational orientation, with a non-round form the orientation of thecolumn usually is important and must be according to the builder's orarchitect's plan. Additionally, because the insert assembly 120 cannotbe seen from outside of the form once the form has been verticallyerected, the contractor does not know whether the insert assembly isproperly oriented and centered with respect to the desired orientationand center location for the column to be produced.

In accordance with the present invention, these problems are addressedby providing a locating template 130, 230, 330, 430, 530 (see thevarious embodiments in FIGS. 3-7, respectively) configured to bepositioned in the bottom opening of the channel C proximate the bottomend of the outer tube 110. The locating template has an outer peripheralsurface 132, 232, 332, 432, 532 having sides defining a non-round shapefor the locating template. The size and shape of the locating templateis such that the template can be fit into the non-round opening of thechannel C with a frictional engagement with the inner surface of theinsert assembly at the channel opening. Additionally, the shape of thelocating template is such that the template can be fitted into theopening of the channel in only one orientation or in a limited number oforientations in all of which the geometric center of the locatingtemplate coincides (neglecting small manufacturing tolerances) with thegeometric center of the channel C. The locating template defines aplurality of indicators that are visually discernable when the locatingtemplate is positioned in the opening of the channel (prior to the formbeing vertically erected on the ground). The indicators indicate thegeometric center of the locating template and thus of the channelopening. Based on the indicators, the outer surface of the outer tube110 can be marked with marks 112 (two of which are shown in FIG. 1) thatcan be aligned with a crosshair 20 that has previously been marked onthe ground to indicate the desired location of the center of the columnand the desired orientation of the column. In this manner, it is assuredthat the insert assembly 120 within the outer tube 110 is properlycentered and oriented.

The locating template 130 of FIG. 3 has indicators 134, 136, 138 each ofwhich is formed in or on the outer peripheral surface 132 of thelocating template. In this embodiment, the locating template has agenerally square shape for use with a square concrete form such as shownin FIG. 2; thus, the locating template has four sides. The indicator 134is located so as to bisect one side, the indicator 136 is located so asto bisect a second side, and the indicator 138 is located so as tobisect a third side. The indicators 134, 136, 138 can be grooves formedin the outer peripheral surface 132 as illustrated; alternatively, theindicators could be printed (e.g., with ink or the like) on the outerperipheral surface. The locating template 130 also has a fourthindicator 140 on a fourth side of the locating template that isdifferent from the other indicators. The indicator 140 comprises a slotformed entirely through the thickness of the locating template, i.e.,from one major face to the opposite major face of the locating template,but only partway across the width of the locating template. In thisembodiment, the locating template also includes an aperture 142extending entirely through the thickness at or near the geometric centerof the locating template, and the slot 140 extends from the outerperipheral surface 132 to the aperture 142 and connects with theaperture. The slot 140 can be formed by a hot wire that is also used forcutting the aperture 142. The aperture 142 facilitates removal of thelocating template from the channel, such as by inserting one or morefingers or a tool into the aperture and pulling the insert out of thechannel.

With reference to FIG. 8, in operation, the locating template 130 isinserted into the bottom opening of the insert assembly 120. Theindicators 134, 136, 138, 140 establish a crosshair, i.e., a line 144extending from the indicator 134 to the indicator 138, and aperpendicular line 146 extending from the indicator 136 to the indicator140. The contractor can use a ruler or straightedge to facilitatemarking where these lines intersect the outer surface of the outer tube110, and using a pen, pencil, or other implement the contractor can markthe outer surface of the tube at two or more locations (e.g., see marks112 in FIG. 1). Next, the locating template is removed from the form.Finally, the form 100 is vertically erected on the ground by aligningthe marks 112 on the outer tube with the crosshair 20 on the ground.External bracing (not shown) or the like can then be used to affix theform in the desired location and orientation.

Locating templates of other configurations and designs can be used inaccordance with the invention. For example, FIG. 4 shows a locatingtemplate 230 having an overall configuration similar to the locatingtemplate 130, but having a different configuration of indicators. Moreparticularly, the locating template 230 includes a first indicator 234formed on or in the outer face (i.e., the major face that issubstantially normal to a central longitudinal axis of the form 100 andfaces away from the interior of the form when the locating template isinserted into the form) of the locating template, and a second indicator236 formed on or in the outer face of the locating template. Theindicator 234 is a straight line extending from one side of the locatingtemplate to an opposite side thereof, bisecting these two sides. Theindicator 236 is a straight line extending perpendicular to theindicator 234 and bisecting the remaining two sides of the locatingtemplate. As shown, the indicators 234, 236 can comprise grooves (e.g.,formed by a hot wire) in the outer face; alternatively, the indicatorscould be printed on the outer face or otherwise formed on or in theouter face. Usage of the locating template 230 is substantially the sameas usage of the locating template 130 previously described.

FIG. 5 shows yet another locating template 330 in accordance with theinvention. The locating template 330 includes indicators 334, 336, 338,340 generally similar to indicators 134, 136, 138, 140 of the locatingtemplate 130, except that indicators 334, 336, 338 are formed as groovesor notches in the corners formed between the outer peripheral surface332 and the outer face of the locating template and do not extend alongthe outer peripheral surface 332 along the entire thickness of thelocating template between the outer face and the opposite inner face; incontrast, indicators 134, 136, 138 of locating template 130 do extendthe full thickness of the locating template along the outer peripheralsurface 132. Additionally, the generally centrally located aperture 342of locating template 330 has a generally diamond shape as opposed to thegenerally rectangular shape of aperture 142 of locating template 130.Usage of the locating template 330 is substantially the same as usage ofthe locating template 130 previously described.

FIG. 6 depicts a locating template 430 generally similar to the locatingtemplate 330 of FIG. 5, but having indicators 434, 436, 438 formed asgrooves extending along the outer peripheral surface 432 over the fullthickness of the template. Additionally, the locating template 430 hasfour additional indicators 434 a, 436 a, 438 a, 440 a that are clocked45° with respect to the indicators 434, 436, 438, 440. Moreparticularly, a line extending between indicators 434 a and 438 a makesa 45° angle with respect to a line extending between indicators 434 and438. A line extending between indicators 436 a and 440 a makes a 45°angle with respect to a line extending between indicators 436 and 440.The provision of eight indicators facilitates aligning the locatingtemplate and concrete form with a 45° line that some contractors mark onthe ground.

A locating template 530 in accordance with yet another embodiment isshown in FIG. 7. The locating template 530 differs from those previouslydescribed in that its overall plan shape is not substantiallycomplementary to the shape of the channel C in the concrete form as istrue for the locating templates 130, 230, 330, 430. Rather, the locatingtemplate 530 has a “cross” shape that is still able to frictionallyengage the inner surface of the insert assembly. Further, like the otherlocating templates, the template 530 can fit into the channel defined bythe insert assembly in a limited number of orientations (in thisembodiment, four orientations angularly clocked 90° with respect to eachother), and the geometric center of the template coincides with thegeometric center of the channel in all of those orientations. Thelocating template 530 has the advantages that it uses less material thanthe previously described templates and it can be cut, along with aplurality of identical templates, from a large sheet of material withless waste than the other templates (the main waste being the materialcut out to form the central aperture 542). The locating template 530includes indicators 534, 536, 538, 540 formed as grooves in the outersurface 532, similar to the corresponding indicators 434, 436, 438, 440of the FIG. 6 embodiment.

The locating templates 130, 230, 330, 430, 530 can be formed of anysuitable material, including but not limited to polymer foam materials.A non-limiting example of a suitable polymer foam material is EPS.

In addition to being useful for facilitating proper alignment andorientation of a non-round concrete form, the locating templates inaccordance with the invention also have utility in shipping of formsfrom one location to another. In many cases, a multitude of forms may beshipped in a truck or trailer, stacked one upon another. The weight ofoverlying forms bearing on underlying forms can cause the underlyingforms to be squeezed out of round (e.g., oval or egg-shaped), which isundesirable. In accordance with the invention, a locating template asdescribed can be inserted into each end of each form. The locatingtemplates provide additional structural support at the ends of the formsand help resist deformation as described.

Many modifications and other embodiments of the inventions set forthherein will come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the inventions are not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

1. A concrete form assembly for pouring a concrete column of non-roundcross-section, comprising: a form having a circular cylindrical outersurface and having an inner surface defining a central channel ofnon-round cross-section for defining the desired cross-section for aconcrete column, the channel defining a first opening of non-round shapeat one end of the form and an opposite second opening of non-round shapeat an opposite end of the form; and a first locating template positionedin the first opening of the channel, the first locating templateincluding an outer peripheral surface frictionally engaged with theinner surface of the form at the first opening so as to retain the firstlocating template in the first opening, and the first locating templatedefining a plurality of indicators that are visually discernable whenthe first locating template is positioned in the first opening, theindicators indicating a geometric center of the first locating templateand thus of the first opening.
 2. The concrete form assembly of claim 1,wherein the non-round shape of the first locating template is square orrectangular having four sides, and the indicators are arranged toindicate a location for each of the four sides of the first locatingtemplate at which said side is bisected.
 3. The concrete form assemblyof claim 1, wherein the first locating template has an outer facesubstantially normal to a central longitudinal axis of the form andfacing away from an interior of the form, and an opposite inner face, athickness of the first locating template being defined between the outerand inner faces.
 4. The concrete form assembly of claim 3, and whereinat least one of the indicators is at or on the outer face.
 5. Theconcrete form assembly of claim 3, wherein the indicators comprisestraight grooves formed in the outer face.
 6. The concrete form assemblyof claim 3, wherein the indicators comprise straight lines printed ormarked on the outer face.
 7. The concrete form assembly of claim 3,wherein one of the indicators comprises a slot formed entirely throughthe thickness of the first locating template and extending from theouter peripheral surface at one side of the first locating templatepartway toward an opposite side thereof.
 8. The concrete form assemblyof claim 7, wherein the first locating template defines an apertureextending through the thickness.
 9. The concrete form assembly of claim8, wherein the aperture is positioned generally centrally in the firstlocating template and the slot extends to and connects with theaperture.
 10. The concrete form assembly of claim 3, wherein at leastsome of the indicators comprise notches formed in the outer peripheralsurface of the first locating template.
 11. The concrete form assemblyof claim 3, wherein the first locating template defines an apertureextending through the thickness.
 12. The concrete form assembly of claim11, wherein at least some of the indicators comprise notches formed inthe outer peripheral surface of the first locating template.
 13. Theconcrete form assembly of claim 1, further comprising a second locatingtemplate substantially identical to the first locating template andpositioned in the second opening of the channel.
 14. The concrete formassembly of claim 1, wherein the first locating template is made ofpolymer foam.
 15. A device for use with a concrete form for forming anon-round concrete column, the form having a circular cylindrical outersurface and having an inner surface defining a central channel ofnon-round cross-section for defining the desired cross-section for aconcrete column, the channel defining a first opening of non-round shapeat one end of the form and an opposite second opening of non-round shapeat an opposite end of the form, the device comprising: a first locatingtemplate configured to be inserted into either of the first and secondopenings of the channel, the first locating template including an outerperipheral for frictionally engaging an inner surface of the form at thefirst opening so as to retain the first locating template in the firstopening, and the first locating template defining a plurality ofindicators that are visually discernable when the first locatingtemplate is positioned in the first opening, the indicators indicating ageometric center of the first locating template and thus of the firstopening.
 16. The device of claim 15, wherein the non-round shape of thefirst locating template is square or rectangular having four sides, andthe indicators are arranged to indicate a location for each of the foursides of the first locating template at which said side is bisected. 17.The device of claim 15, wherein the first locating template has an outerface substantially normal to a central longitudinal axis of the form andfacing away from an interior of the form, and an opposite inner face, athickness of the first locating template being defined between the outerand inner faces.
 18. The device of claim 17, and wherein at least one ofthe indicators is at or on the outer face.
 19. The device of claim 17,wherein the indicators comprise straight grooves formed in the outerface.
 20. The device of claim 17, wherein the indicators comprisestraight lines printed or marked on the outer face.
 21. The device ofclaim 17, wherein one of the indicators comprises a slot formed entirelythrough the thickness of the first locating template and extending fromthe outer peripheral surface at one side of the first locating templatepartway toward an opposite side thereof.
 22. The device of claim 21,wherein the first locating template defines an aperture extendingthrough the thickness.
 23. The device of claim 22, wherein the apertureis positioned generally centrally in the first locating template and theslot extends to and connects with the aperture.
 24. The device of claim17, wherein at least some of the indicators comprise notches formed inthe outer peripheral surface of the first locating template.
 25. Thedevice of claim 17, wherein the first locating template defines anaperture extending through the thickness.
 26. The device of claim 25,wherein at least some of the indicators comprise notches formed in theouter peripheral surface of the first locating template, each of thenotches extending to an edge at which the outer peripheral surface joinswith the outer face.
 27. The device of claim 15, wherein the firstlocating template is made of polymer foam.